Method and apparatus for making textured yarn and product



J. R. FISH, SR

May 31, 1966 METHOD AND APPARATUS FOR MAKING TEXTURED YARN AND PRODUCTFiled June 1, 1959 2 Sheets-Sheet l COMPRESSED VAR/ABLE SPEED M0701?CONSTANT SPEED MOTOR INVENTOR Jose 27k Raymond Eds/n52: BY R WW iATTORNEY May 31, 1966 J. R. FISH, SR

METHOD AND APPARATUS FOR MAKING TEXTURED YARN AND PRODUCT 2 Sheets-Sheet2 Filed June 1, 1959 SPEED M070 VAR/ABLE INVENTOR dasgv/z RaymondPKG/@571 i al y/ 7 ATTORNEY United States Patent Ofiice 3,253,396Patented May 31, 1966 3,253,396 METHOD AND APPARATUS FOR MAKING TEXTUREDYARN AND PRODUCT Joseph Raymond Fish, Sr., Woodbridge, Conn, assignor,by mesne assignments, to Beaunit Corporation, New York, N.Y., acorporation of New York Filed June 1, 1959, Ser. No. 817,180 13 Claims.(Cl. 57-34) This invention relates to blown or textured yarn. Moreparticularly it relates to combination textured yarn in which lengthshaving only moderately blown or textured elfect alternate with lengthshaving a more pronounced blown or textured eifect.

An object of this invention is to provide a blown or textured yarn inwhich lengths of only moderately textured yarn alternate with lengthshaving a more pronounced textured eifect.

A further object of this invention is to provide a combination blown ortextured yarn in which lengths having only a moderately textured eifectalternate with lengths having a more pronounced textured effect.

A still further object of this invention is to provide a blown ortextured yarn in which random lengths having only a moderately texturedeffect alternate with random lengths having a more pronounced texturedeffect.

Still another object of this invention is to provide a combination blownor textured yarn containing core yarn and wrap or surface effect yarn inwhich random lengths having only a moderately textured effect alternatewith random lengths having a more pronounced textured effect.

Another object of this invention is to provide a method of producingblown or textured yarn in which lengths of only moderately textured yarnalternate with lengths having a more pronounced textured effect.

Still another object of this invention is to provide 'a method ofproducing combination blown or textured yarn in which lengths havingonly a moderately textured effect alternate with lengths having a morepronounced textured effect.

A further object of this invention is to provide a method of producingblown or textured yarn in which random lengths having only a moderatelytextured eifect alternate with random lengths having a more pronouncedtextured effect.

A further object of this invention is to provide a method of producingcombination blown or textured yarn containing core yarn and wrap orsurface effect yarn in which random lengths having only a moderatelytextured effect alternate with random lengths having a more pronouncedtextured effect.

Another object of this invention is to provide a yarn texturingapparatus having separate means for advancing core yarn and wrap oreffect yarn to a common yarn bulking gas jet.

Still another object of this invention is to provide a yarn texturingapparatus having means for advancing core yarn to a yarn bulking gasjet, separate means for advancing wrap or effect yarn to the same gasjet, and means for producing temporary increases in the rate at which.the wrap or effect yarn is advanced to the gas jet.

A further object of this invention is to provide a yarn texturingapparatus having means for advancing core yarn to a yarn bulking gasjet, separate means for advancing wrap or effect yarn to the same gasjet, and means for producing random temporary increases in the rate, atwhich the wrap or effect yarn is advanced to the gas jet.

Other and further objects of this invention will be apparent to thoseskilled in the art to which it relates from the following specificationand claims and from the draw- A wide variety of textured yarns may beproduced by feeding spun or multifilament yarn, or combinations thereof,to a bulking jet where gas turbulence, produced by introducing gas underpressure into the bulking zone of the jet, blows, bulks, lofts or fluffsthe yarn. It is necessary that the rate at which the yarn is fed to thejet be greater than the rate at which the textured yarn is withdrawnfrom the jet to permit yarn contraction in the bulking zone. Suchtextured yarns and the apparatus and the methods used in theirproduction are described in United States Patents No. 2,783,609, No.2,807,862, No. 2,829,420, No. 2,852,906, No. 2,869,967, No. 2,874,443,No. 2,874,444, No. 2874,445, and No. 2,884,756. The nature of thetextured effect produced depends on the type of yarn or yarns used, thetype of gas bulking jet used, the gas pressure, and the amount,

of overfeed, i.e., the difference between the rate at which the yarn isfed to the jet and the rate at which it is withdrawn from the jet, as isexplained in detail in the patents cited.

The methods described in these patents may be modified to give texturedproducts which have a second novelty eifect. For example, a pulsatingair jet may be used to produce thick and thin textured yarn. Nubbytextured yarn may be produced by withdrawing the yarn from the jet at aconstant rate while intermittently and at random interrupting the gasflow to the jet, by varying at random intervals the rate at which thetextured yarn is withdrawn from the jet, or by withdrawing the texturedyarn from the jet at a very low rate to permit an excessive amount ofyarn construction in the jet. Textured yarn having alternating smoothand bulked lengths may be produced by intermittently impulsing the yarn.

I have found, unexpectedly, that the various gas bulking devicesdisclosed in the patents cited may be used to produce noveltycombination yarns in which slightly textured lengths of effect yarnalternate with lengths having a more pronounced textured effect. Thenumber of alternating lengths of differently textured etfect yarnforming a repeat may be so small that the novelty effect has a regularappearance, or it may be so great that the effect appears to be random.It is generally required that the effect in a novelty yarn shall appearto be random.

My apparatus consists of a gas bulking jet, operated as disclosed in thecited patents, means for feeding one or more core yarns to the jet,separate means for feeding one or more wrap or surface elfect yarns tothe same jet, means for temporarily increasing the rate at which theefiect yarn is fed to the jet, and means for withdrawing the texturedcombination yarn from the jet and packaging it. The means fortemporarily increasing the speed at which theeffect yarn is fed to thejet may act at regular intervals to give a visible pattern, or at randomintervals to give an elfect having no apparent pattern.

*I feed the core yarn to the jet at a suitable fixed rate and I feed thewrap or elfect yarn to the same jet at a faster basic rate. At intervalsI temporarily increase the rate at which the effect yarn is fed to thejet. During such periods of accelerated feed the bulking effect obtainedin the effect yarn becomes more pronounced. I withdraw the texturedcombination yarn from the jet at a rate which is less than the rate atwhich the core yarn is fed to the jet so that the core yarn has auniform moderately textured effect while the effect yarn has lengthstextured at least slightly more than the core yarn, alternating withlengths having a more pronounced texture. The rates at which the coreand effect yarns are fed to the jet and the rate at which thecombination yarn is withdrawn from the jet may be varied widely as longas the relations just mentioned are maintained.

The core yarn should be one which may be textured at least slightlywhile the wrap or effect yarn should be one which may be texturedreadily, preferably to a greater degree than the core yarn. A widevariety of fiber types, yarn types, yarn sizes, yarn colors, etc., maybe used, separately or in combination, to produce my novelty bulkedyarns. Novelty yarns, such as crimped or self-crimping viscose rayon,may be used in the production of my combination yarn. The fiber typeswhich may be used in the production of my novelty yarn includeregenerated cellulose rayon, cellulose ester yarn, regenerated caseinyarn, nylon, polyester yarn, silk, Fiberglas (a glass yarn), Fortisan(high tenacity saponified cellulose acetate yarn), Orlon (polyacrylonitrile yarn), Polythene (polyethylene yarn), and Vinyon N (vinylchloride-acrylonitrile copolymer yarn).

Further details of this invention will be apparent to those skilled inthe art to which it relates from the following specification, claims anddrawing.

Referring to the drawing briefly:

FIG. 1 is a front schematic view of an apparatus incorporating thisinvention;

FIG. 2 is a schematic wiring diagram of this apparatus, showing thecontrol system for the variable speed motor; and

FIG. 3 is a sectional view of the gas bulking jet.

Referring to FIG. 1 of the drawing it will be seen that the apparatusconsists essentially of a pair of angle axis thread advancing rollers10, 11 driven by constant speed motor 12, a second pair of angle axisthread advancing rollers 13, 14 driven by a variable speed motor 15provided with a speed control system to be described subsequently, gasbulking jet 16, and drum driven take-up winder 17.

As shown in FIG. 1, core yarn 18 is withdrawn from supply cone 19,passed through a pig tail thread guide 20 and a spring-urged disc-typetensioning device 21, is wrapped about angle axis thread advancingrollers 10, 11 a suitable number of times, and then passed through pigtail thread guide 22 at a suitable constant rate to gas bulking jet 16.Wrap or effect yarn 23 is withdrawn from supply cone 24, passed througha pig tail thread guide 25 and a spring-urged disc-type tensioningdevice 26, is wrapped about angle axis thread advancing rollers 13, 14 asuitable number of times and then passed through pig tail thread guide27 to gas bulking jet 16 at a basic rate which is faster than the rateof core yarn feed. From time to time the rate of effect yarn feed isincreased sharply by means of the control system shown in FIG. 2. As iswell-known in the art the angle axis thread advancing rolls positivelyfeed or advance yarn wrapped about them a sufficient number of times toavoid slippage.

Compressed air, supplied to bulking jet 16, shown in detail in FIG. 3,through pipe 28, passes through jet passage 29 and constricted jetpassage 30. Hollow needle 31, provided with head portion 32 so that itcan be adjustably positioned in the jet to obtain the desired bulkingeffect, provides a yarn passage into constricted passage 30 of the jet,entering the same at an angle to its longitudinal axis. Towards its freeend 33 half of hollow needle 31 is cut away so that the yarn can bewithdrawn from the needle while free end 33 is positioned in cavity 34in the wall of constricted passage 30. The gas stream 4 becomesturbulent in constricted passage 30 and blows the yarn about, texturingit to the extent that its nature and the amount of overfeed permit. Yarntexturing jets of this type are sold by Enterprise Machine Company ofNew Castle, Delaware, under their designation Type 42AR.

Returning now to the description of the travel of the yarn through theapparatus, it will be seen that core yarn 18 and the wrap or effect yarn23 are combined in hol-' low needle 31 of jet 16 and pass through thehollow needle and constricted jet passage 30 together. Texturedcombination yarn 35 is withdrawn from passage 30 at approximately aright angle to its longitudinal axis at a rate less than therate of coreyarn feed.

After it leaves jet 16 combination yarn 35 is passed about thread guide36, through a pair of disc-type thread tension devices 37, 38, aboutthread guide 39, through traverse guide 40, and is wound on core 41 bymeans of a conventional drum-driven take-up winder 17.

The control system for motor 15, shown in FIG. 2, consists of a PTS3Production Timer sold by Electro- -Mechanical Engineering Company ofCharlotte, North Carolina, and a modified Type W2-400 Variactransformer, sold by General Radio Company of Cambridge, Massachusetts.

The Variac transformer consists of a single layer winding 42. on atoroidal iron core. Contact brush 43, mounted on rotatable arm 44, tapsoff the desired voltage from winding 42. A second contact brush 45,mounted on rotatable arm 46, which has an insulated portion 47, taps offa higher voltage from the same winding.

The design or pattern wheel of the Production Timer" has front side 48and back side 49, each provided with a rim to which projecting segments(cams) 50, spaced as desired, may be secured. The diameter of thepattern wheel and projecting segments is 10 inches. A total of 62 of thesegments supplied with this device may be attached to each rim of thewheel. It is convenient to divide each rim into 62 equal spaces,numbering them 1 to 62, so that the pattern may be represented by thenumbers of the spaces to which segments are attached. Of course largeror smaller segments may be used with this pattern wheel. Motor 51,operating at 2.4 revolutions per minute, is connected with the patternwheel shaft by a 1:1 drive. Switches 52 and 53, positioned adjacent thefront and back sides of the pattern wheel, respectively, are closed bythe segments as they pass over them. Cam 54, driven from the patternwheel shaft by a 1:168 drive 55, actuates double pole, single throwswitch 56 through member 57.

Electric power from a suitable source is connected to the inputterminals of the Variac transformer. One contact 60 of cam-actuatedswitch 56 is connected in series with switch 53 and relay 61. The othercontact 62 of cam-actuated switch 56 is connected in series with switch52 and the same relay 61. Double pole, double throw switch 63 isactuated by relay 61. Contacts 64 and 65 of switch 63 are connected withcontact brush 43 of the Variac transformer and rectifier 58 and thevariable speed motor, respectively, and contacts 66 and 67 of i switch63 are connected with contact brush 45 of the Variac transformer andrectifier 58 and the variable speed motor, respectively.

It will now be seen that the position of cam-actuated switch 56determines whether relay 61 is actuated by the segments on the frontside of the wheel, acting on switch 52, or by the segments on the backside of the wheel, acting on switch 53. When the relay is not energizedthe variable speed motor 15 is driven by current tapped off by contactbrush 43 through contacts 64 and 65. As long as the relay is energizedswitch 63 is thrown so that the motor 15 is operated at an increasedspeed by current tapped off by contact brush 45 through contacts 66 and67. The arms bearing the contact brushes may be fastened together sothat the difference between the two rates of effect yarn feed willremain constant when the V'ariac setting is changed. Increasing thespeed of motor increases the rate at which effect yarn is fed to the jetand consequently increases the textured effect obtained in this yarn.

The following examples illustrate the manner in which the invention iscarried out.

EXAMPLE 1 Using the apparatus described above and shown in the drawing,core yarn consisting of one end of 300/75 2 turn bright celluloseacetate yarn was wrapped 3 /2 times about the angle axis threadadvancing rollers and fed to the Type 42AR jet at about 37 yards perminute. Wrap or effect yarn consisting of 2 ends of 300/75 2 turn goldcellulose acetate yarn was wrapped 3 /2 times about the second set ofangleaxis thread advancing rollers and was fed to the same jet at abasic rate of about 47 yards per minute. From time to time the controlsystem temporarily increased the speed of the variable speed motor sothat the wrap or effect yarn was fed to the jet at the accelerated rateof about 134 yards per minute. combination yarn was withdrawn from thejet at about 34 yards per minute. The air supplied to the jet was undera pressure of about 55 pounds per square inch.

Segments were secured to the front side of the design or pattern wheelin spaces 4, 11, 18, 25, 32, 37, 43, 50, 56 and 57, and to the back sidein spaces 1, 7, 14, 21, 27, 33, 40, 46, 52, and'59.

EXAMPLE 2 One end of 150/40 3 turn bright cellulose acetate yarn and oneend of 70/34 /2 turn semidull nylon was used as core yarn, and one endof 300/75 2 turn gold cellulose acetate yarn and one end of 150/40 3turn bright cellulose acetate yarn was used as effect yarn. These yarnswere processed as in Example 1.

EXAMPLE 3 One end of 150/40 3 turn bright viscose rayon and one end of70/34 0 turn semidull Dacron polyester yarn was used as core yarn, andone end of 300/80 3 turn bright viscose rayon and one end of 150/40 3turn bright viscose rayon was used as effect yarn. These yarns wereprocessed as in Example 1, except that about 45-50 pounds per squareinch compressed air was. used in the 'et.

1 The combination yarns thus obtained had alternating moderately andstrongly textured lengths of effect yarn, apparently distributed atrandom.

The novel effect obtained may be varied widely for it depends on theyarns used, the amounts of overfeed, in particular the differencesbetween the two rates of effect yarn overfeed as governed by the settingof the control system, the type of bulking device used, the air pressureused in the jet, etc., each of which may be varied widely as explainedabove.

A one-piece machine is shown and described but it will be recognizedthat this invention may be embodied in a multi-place machine. In such amachine an electrical or a pneumatic clutch may be used to vary thespeed of the drive shaft for the effect yarn thread advancing rollers,or these may be driven by a direct current motor with a variableresistance, in each case using a suitable control device to obtain thedesired speed changes. T-hread advancing means and take-up devices otherthan those described may also be used, in each case in connection withsuitable thread guides and tension devices. The specific type of bulkingdevice used to obtain the turbulent gas stream will depend on the effectdesired.

While I have described this invention in detail with respect to certainembodiments thereof, it is not desired to limit it to the detailsdescribed and illustrated except insofar as they are set forth in thefollowing claims.

The

What is claimed is:'

1. A method of making textured yarn which comprises positively advancinga first yarn into a yarn bulking zone, positively advancing a secondyarninto the same yarn bulking zone at a basic rate greater than thefirst rate of advance, producing a series of temporary increases overthe basic rate of advance of the second yarn, bulking the yarns thus fedinto the bulking zone, and withdrawing the combined textured yarns fromthe bulking zone at a rate lower than the first rate of advance, wherebythe first yarn is at least slightly textured, and the second yarn isbulked to have a basic texture more pronounced than that of the firstyarn and a series of lengths having a texture more pronounced than thebasic texture.

2. A method as defined in claim 1 wherein the temporary increases in therate at which the second yarn is advanced to the bulking zone areproduced substantially at random, whereby the second yarn texture variations have a random appearance.

3. A method as defined in claim 1 wherein the first yarn is advanced tothe bulking zone at a constant rate.

4. A method as defined in claim 2 wherein the first yarn is advanced tothe bulking zone at a constant rate.

5. Yarn texturing apparatus comprising essentially a yarn bulkingdevice, a first means for positively advancing yarn to said bulkingdevice, means for driving said first yarn advancing means, a secondmeans for positively advancing yarn to said bulking device, means fordriving said second yarn advancing means at a basic rate greater thanthat of said first yarn advancing means, means for repeatedlytemporarily increasing the rate of advance of the second yarn over thebasic rate, and means for withdrawing combination textured yarn fromsaid bulking device at a lower rate than said first yarn advancingdevice supplies yarn thereto, whereby the first yarn is at leastslightly textured, and the second yarn has a basic texture morepronounced than that of the first yarn and a series of lengths having atexture more pronounced than the basic texture.

6. Yarn texturing apparatus as defined in claim 5 having means fortemporarily increasing the rate of advance of the second yarn over thebasic rate at substantially random intervals, whereby the second yarntexture variations have a random appearance.

7. Yarn texturing apparatus as defined in claim 5 having means fordriving said first yarn advancing means at a constant rate.

8. Yarn texturing apparatus as defined in claim 6 having means fordriving said first yarn advancing means at a constant rate.

9. Yarn texturing apparatus as defined in claim 5 wherein said yarnbulking device comprises a jet adapted to create a zone wherein yarn isbulked and means for supplying gas under pressure to said jet.

10. Yarn texturing apparatus as defined in claim 6 wherein said yarnbulking device comprises a jet adapted to create a zone wherein yarn isbulked and means for suplying gas under pressure to said jet.

11. Yarn texturing apparatus comprising a jet adapted to create a zonewherein yarn is textured, means for supplying gas under pressure to saidjet, a first pair of angle axis rollers for positively advancing a firstyarn to said jet, means for driving said first pair of angle axisrollers at a constant rate, a second pair of angle axis rollers forpositively advancing a second yarn to said jet, means for driving saidsecond pair of angle axis rollers at a basic rate greater than that ofsaid first pair of angle axis rollers, means for producing a randomseries of temporary increases in the rate of advance of the second yarn,and means for withdrawing combination textured yarn from said jet at alower rate than said first pair of angle axis rollers supplies yarnthereto, whereby the first yarn is at least slightly textured; and thesecond yarn has a basic texture more pronounced than that of the firstyarn and a series of random lengths having a texture more pronouncedthan the basic texture.

. 12. Yarn containing at least one textured core end and- ReferencesCited by the Examiner UNITED STATES PATENTS 788,292 4/ 1905 Verlenden57-91 2,852,906 9/1958 Breen 57-34 2,864,230 12/1958 Moore 57-1572,869,967 1/1959 Breen 57-140 Grieset 57-34 Hilbert 57-140 Field 57-34Breen 57-34 FOREIGN PATENTS Australia. Belgium. Great Britain. GreatBritain. Great Britain.

MERVIN STEIN, Primary Examiner.

l5 RUSSELL C. MADER, Examiner.

H. G. GARNER, Assistant Examiner.

5. YARN TEXTURING APPARATUS COMPRISING ESSENTIALLY A YARN BULKINGDEVICE, A FIRST MEANS FOR POSITIVELY ADVANCING YARN TO SAID BULKINGDEVICE, MEANS FOR DRIVING SAID FIRST YARN ADVANCING MEANS, A SECONDMEANS FOR POSITIVELY ADVANCING YARN TO SAID BULKING DEVICE, MEANS FORDRIVING SAID SECOND YARN ADVANCING MEANS AT A BASIC RATE GREATER THANTHAT OF SAID FIRST YARN ADVANCING MEANS, MEANS FOR REPEATEDLYTEMPORARILY INCREASING THE RATE OF ADVANCE OF THE SECOND YARN OVER THEBASIC RATE, AND MEANS FOR WITHDRAWING COMBINATION TEXTURED YARN FROMSAID BULKING DEVICE AT A LOWER RATE THAN SAID FIRST YARN ADVANCINGDEVICE SUPPLIES YARN THERETO, WHEREBY THE FIRST YARN IS AT LEASTSLIGHTLY TEXTURED, AND THE SECOND YARN HAS A BASIC TEXTURE MOREPRONOUNCED THAN THAT OF THE FIRST YARN AND A SERIES OF LENGTHS HAVING ATEXTURE MORE PRONOUNCED THAN THE BASIC TEXTURE.
 12. YARN CONTAINING ATLEAST ONE TEXTURED CORE END AND AT LEAST ONE TEXTURED EFFECT END INWHICH LENGTHS HAVING